Digital I/O and Analog I/O

Automation has become the backbone of almost all

industries worldwide. Digital IO and analog IO are
the most basic terms of any PLC/DCS based
control and microcontroller-based applications.
A PLC collects data from the field process it as pre-
programmed and produces one or more outputs.
The data that is collected from the field is
considered as the input to the PLC and the data
passed from PLC to the field is considered as its
output.
PLCs has sophisticated electronic blocks/cards for
collecting these data and producing the outputs.
This article is meant to give you a basic idea on
various types of inputs in PLC and the difference
between them.
Digital IO and analog IO classification
Basically, PLC inputs and outputs are classified as
follows:
 Digital Input – DI
 Digital Output – DO
 Analogue Input – AI
 Analogue output – AO

Difference between DI, DO, AI and AO

Digital Input – DI

Digital inputs are binary inputs (0 or 1) that are

applied to the PLC. Binary inputs are basically
voltages, varying from 5V to 230V depending upon
the type of card used. In simple words, any push-
button, switches or sensors produces digital inputs
to a PLC. Digital inputs are used to check the status
of any devices whether it is ON or OFF. For an Input
module of 24Vdc, 0Vdc acts as OFF state (Binary
0) and 24Vdc acts as ON state (Binary 1).
Digital Output

Digital outputs are binary outputs (0 or 1) from the

PLC. It is a processed control output from the PLC
to the field. It is used to ON or OFF any piece of field
equipment. DO is like a contact of a relay when the
pre-programmed conditions are satisfied the
contacts are closed. DO can be used to operate
solenoid valves, relays, indicating lamps or as a
command to any other devices.
Analog Input – AI
Analog input is a continuous input from the field to
the PLC. Unlike digital signals, is not a constant
voltage signal. It can vary depending on the field
conditions. The commonly used analogue signals
are 4-20mA signal and 0-10Vdc Signal. Depending
on the field conditions the input signal can vary
between 4-20mA or 0-10Vdc. For Example, if you
are monitoring a pressure of water flowing through
a pipe using a pressure transmitter of range 0-10
Bar, the transmitter will give a signal between 0 and
10V proportional to the pressure in the pipe.

Analog Output

Analogue output is a continuous output from PLC to

the field devices. For example, if you have a
variable frequency drive and you want to give a
speed reference signal to it you can use analogue
output. Otherwise, if you are measuring the
pressure using analogue input as explained above
and you would like to display it on an analogue
meter you can use an analogue output of PLC.
Difference between DI and AI
As explained above digital input and analogue
input are data collected from the field. Digital input
is binary in nature, either it can be ON or it can be
OFF. Either it can be 0V or it can be 24V based on
the type of IO module used. Switches, sensors etc.
are examples of digital input. Analog signal is a
time-varying signal. It can be varying between 0-
10V or 0-20mA based on the design. Transduces
are examples of analogue input devices.
Difference between DO and AO
A digital output is binary in nature, either it can be
ON or it can be OFF. Either it can be 0V or it can be
24V based on the type of IO module used. Analog
signal is a time-varying signal. It can be varying
between 0-10V or 0-20mA based on the design.
Pneumatics technology is a popular option for
machinery and industrial devices because it is
clean, fast, and economical. The most common
form of accomplishing pneumatically driven motion
is by applying or removing air pressure to extend or
retract a cylinder, but there are also rotary actuators
and even air motors. All of these devices can be
automated using digital controllers integrated to
command the pneumatics and make the equipment
move as desired.
This motion is often simply a discrete on-or-off
mode, as opposed to a continuously variable
analog mode, but that’s not always the case. Linear
actuators can be configured for multiple
intermediate stops, or with modulating options for
variable positioning. For process control valves,
pneumatic valve positioners can perform this
function, and they often need to be monitored to
ensure accurate activation.
Many users find that they can take full advantage of
the benefits offered by pneumatic fluid power
delivery by integrating more advanced analog
control features. This article examines how users
can identify opportunities and select the right
components to incorporate analog controls into
their pneumatic systems.
Discrete vs. Analog Signals
For equipment requiring more control complexity
than basic selector switches and indicator lights,
automation is usually performed with smart relays,
programmable logic controllers (PLCs), or
programmable automation controllers (PACs).
These computing devices connect to the outside
world through input/output (I/O) points.
Basic automation needs are most often handled
with discrete signals that are on or off. This can be
a discrete output (DO), such as to command a
solenoid valve, or a discrete input (DI), for
monitoring a limit or pressure switch. Discrete
signals are easy to select, configure, and install,
with the proper voltage being the main concern.
Analog input signals, on the other hand, are
somewhat more complex. Devices such as
analyzers and transmitters produce a range of
signals. Typical analog input signals could be
temperature, level, weight, and speed. However, for
pneumatic systems, common analog inputs are
typically pressure, position and flow. Analog output
signals can be used to command a valve position or
a pressure controller. Incorporating analog signals
requires a little more planning as compared to
discrete signals.
Analog Signal Methods
When incorporating analog signals into a control
system, it is crucial to coordinate the signal method
with the control system, as well as to ensure that
the scaling represents the measured variable
properly.
Standard hardwired analog signals are usually
transmitted as a variable current or voltage. Typical
ranges are 4 to 20 mA, 0 to 10 V dc, or –10 to +10
V dc. For many industries, the 4- to 20-mA signal is
the most popular, and it offers the additional benefit
of positively identifying a failed instrument or wire
connection if the signal ever goes below 4 mA.
Another option is to use a digital communication
protocol if it is available on the pneumatic device
and the controller. Some high-end instruments may
offer an Ethernet-based protocol, like EtherNet/IP.
If individual sensing devices are being used, they
are more likely to offer a local communications
option like IO-Link. This protocol enables the sensor
to perform a traditional hardwired function, but also
transmits an additional digital signal. With the
appropriate hub, this digital signal can be
processed and made available over a higher-level
protocol like EtherNet/IP.
Regardless of how the analog signal is transmitted,
it must be supported and interpreted correctly by
the control systems. The user must identify the
normal sensing range, the possible under-range or
over-range conditions, and the engineering units
involved. For instance, if a designer needs to
monitor a pressure that ranges from 0 to 80 psi, they
may choose a standard pressure transmitter
indicating 0 to 100 psi using 4-20 mA. In this case,
4 mA corresponds to 0 psi while 20 mA corresponds
to 100 psi. Perhaps a signal of less than 3.8 mA or
more than 20.2 mA indicates a wiring or transmitter
problem. These same scaling considerations are
equally applicable to analog output signals.
 Next, we’ll look at control system and field device
specifications to check when working with analog
signals.
Specification Details
Beyond the basic signal method and scaling are
some more involved details. PLCs themselves are
fast and accurate, but when implementing analog
signals the system must be considered as a whole.
In addition to those described above, some other
details impacting analog signals are:
 Resolution
 Accuracy
 Stability
 Electrical isolation
Most PLC analog points offer at least 12-bit
resolution, meaning the signal is processed into
4,096 counts. This is adequate for most
applications, but specific cases may require higher
resolution, typically up to 16-bit, which offers 65,536
counts.
Accuracy and stability are a function of the
transmitter specifications and how well the
transmitter can produce a signal representing the
actual field condition. Best accuracy is obtained
when sizing an instrument to match the application.
For instance, in the previous example where a user
is interested in pressures ranging up to 80 psi, it is
appropriate to select a transmitter able to measure
up to 100 psi. If the user selected a transmitter able
to measure up to 800 psi, they would only be using
the bottom 10% of the available range and could
expect a less accurate signal.
Electrical isolation is partly a function of the
transmitter and the PLC analog points but mostly
involves the field installation. Analog signal cables
are low voltage and are susceptible to electrical
noise, so they should be routed away from higher
voltages. Whenever possible, the analog signal
cables should be the shielded type with the shield
grounded at one end. Even better is to install analog
cables in metal conduit whenever possible, with no
higher-voltage wiring in the conduit.
One additional note is that some instruments are
multi-function, able to provide discrete, analog, and
even digital communications. Once all the signal
and specification details addressed, it is time to look
at where analog signals can be used in pneumatic
systems.
Pneumatic Applications
Pneumatic pressure sensors are plumbed into the
header or line being monitored, and these sensors
then transmit an associated AI signal (Fig. 1). Some
styles are installed in a control panel and require a
tubing run to the process connection. There are
many types of sensors that are configured for field
installation and can be plumbed directly into pipe
fittings. Some pressure transmitters have an on-
board indicator, or users may need to install a
means of local indication.

1. These AutomationDirect ProSense sensors

monitor pressure in many process applications,
providing discrete and analog output signals in
wide measurement ranges for use in both
pneumatic and hydraulic circuits.
The simplest way a control system can use a
pressure transmitter signal is to ensure that a
pneumatic line has the proper pressure to operate
the equipment. More advanced applications may be
used to command and monitor the air pressure
applied to actuators for a mechanism, such as to
provide a variable clamping force for handling
different products.
Determining the analog position directly on-board a
pneumatic linear actuator is possible but not as
common an application, but using position sensors
on the driven equipment is a good option to
determine the exact location of the mechanism.
One very accurate measuring technology uses a
laser to determine distances ranging from
millimeters up to meters (Fig. 2). The control
system can use this signal to extend or retract a
cylinder as needed to achieve the target position.
Once the equipment has moved to the desired
location, air can either be removed from or applied
to both sides of the cylinder as needed to hold
position.
2. Laser distance sensors are a highly accurate
way to sense equipment positions so control
systems can command pneumatics as needed.
Varying pneumatic pressures can be commanded
with a current-to-pneumatic (I/P) transducer (Fig 3).
The current signal is typically 4-20 mA, and I/P
transducers are available with outputs ranging from
a few psi up to more than 100 psi. Analog
pneumatics of this type can be used to operate a
damper control valve, and pneumatics are a good
choice for use in any hazardous area location as an
alternate to intrinsically safe electrical controls.

3. Current-to-pressure (I/P) transducers convert

analog control system signals into varying
pneumatic pressures.
Analog controls can be a very effective addition to
pneumatically actuated equipment, but there are
some best practices to consider. Any critical driven
equipment that relies on analog position feedback
should also have end-of-travel discrete limit
switches and mechanical stops incorporated to
prevent overtravel in the event of a sensor failure.
Similarly, any critical pressures being monitored or
controlled should incorporate high- or low-pressure
switches as an additional precaution.
Analog Controls Provide More Options
Incorporating analog instruments and controls into
pneumatically-operated applications adds an entire
new range of functionality options. Following the
guidelines in this article will help designers select
the right signal range, field device, and control
elements to achieve reliable analog control.
Valves Help Ensure Safe Maintenance
Safety isn’t just a good thing to do; it’s the law.
OSHA Standard 3120, commonly referred to as
lockout-tagout, establishes minimum requirements
for controlling hazardous energy, such as electricity
and compressed air. Employers must establish an
energy-control program to ensure that employees
isolate machines from energy sources and render
them inoperative before any employee services or
maintains them.